Automatic mode switching in a volume dimensioner

ABSTRACT

Dimensioners and methods for dimensioning an object includes capturing, using a dimensioning system with a single sensor, at least one range image of at least one field-of-view, and calculating dimensional data of the range images and storing the results. Wherein, the number of views captured of the object is automatically determined based on one of three modes. The first mode is used if the object is a cuboid, or has no protrusions and only one obtuse angle that does not face the point of view, where it captures a single view of the object. The second mode is used if the object includes a single obtuse angle, and no protrusions, where it captures two views of the object. The third mode is used if the object includes a protrusion and/or more than one obtuse angle, overhang, protrusion, or combinations thereof, where it captures more than two views of the object.

CROSS-REFERENCE TO RELATED APPLICATION

The present application is a continuation application of U.S. patentapplication Ser. No. 15/182,636, filed on Jun. 15, 2016, the entirecontent of which is incorporated by reference into the presentapplication.

FIELD OF THE INVENTION

The present invention relates to systems for determining an object'sphysical dimensions (i.e., dimensioning systems) and, more specifically,to a dimensioning system and method that automatically switches modes toacquire the data necessary for dimensioning in commerce.

BACKGROUND

Generally speaking, determining an item's dimensions is often necessaryas part of a logistics process in commerce (e.g., shipping, storage,etc.). Physically measuring objects, however, is time consuming and maynot result in accurate measurements. For example, in addition to humanerror, measurement errors may result when measuring irregularly shapedobjects or when combining multiple objects into a single measurement. Asa result, dimensioning systems have been developed to automate, orassist with, this measurement.

A dimensioning system typically senses an object's shape/size inthree-dimensions (3D) and then uses this 3D information to compute anestimate of an object's dimensions (e.g., volume, area, length, width,height, etc.). In addition, for irregular objects (or multiple objects),the dimensioning system may compute the dimensions of a minimum boundingbox (MVBB) that contains the object (or objects).

The dimensioning system may sense an object by projecting a lightpattern (i.e., pattern) into a field-of-view. Objects within thefield-of-view will distort the appearance of the light pattern. Thedimensioning system can capture an image of the reflected light-patternand analyze the pattern distortions in the captured image to compute the3D data necessary for dimensioning.

Many dimensioners use optical means of determining the length, width,and height of an object which is usually a cuboid (e.g. a “normal” boxwhere the opposite sides are parallel and perpendicular to the adjacentsides). Some packages, however, are irregular and consequently may notbe able to obtain a single set of dimensions, particularly if one of theangles is obtuse (i.e. greater than 90 degrees). Some systems solve theproblem by utilizing multiple sensors but this is expensive and themultiple sensors limit the size of objects that can be measured. Anothersolution is to program a device always to take measurements of two ormore points of view but this it time consuming for normal boxes orcuboids.

Therefore, a need exists for a single sensor dimensioner with automaticmeans of detecting when multiple views are needed and to automaticallyswitch modes accordingly.

SUMMARY

Accordingly, in one aspect, the present invention embraces a method fordimensioning an object. In the method, a dimensioning system ordimensioner with a single sensor is used to capture at least one rangeimage of an object in at least one field of view. Dimensional data isthen calculated of the at least one range image for all of the at leastone field-of-views and the results are stored. The number of viewscaptured with range images and dimensional data is automaticallydetermined based on one of three modes: a first mode, a second mode, anda third mode. The first mode is automatically used if the object is acuboid, or has no protrusions and only one obtuse angle that does notface the point of view, where the first mode captures a single view ofthe object. The second mode is automatically used if the object includesa single obtuse angle that faces the point of view and no protrusions,where the second mode captures two views of the object. The third modeis automatically used if the object includes a protrusion and/or morethan one obtuse angle, overhang, protrusion, or combinations thereof,where the third mode captures more than two views of the object.

One feature of the method for dimensioning may be to calculate theminimum bounding box (MVBB) from the range images from all of theautomatically determined views.

In another possible embodiment, the method for dimensioning may includedisplaying and/or transmitting the dimensions of the minimum boundingbox (MVBB) for certification in commerce.

In another possible embodiment, the method for dimensioning may includemoving at least one of the dimensioning system and the object (e.g.,either the dimensioning system or the object or both) so that thedimensioning system's field-of-view contains a different view of theobject after capturing one of the views until the determined number ofviews is captured. In select embodiments, this step of moving thedimensioning system or the object (i.e., moving the dimensioning systemand/or the object) may be determined based on one or more of thefollowing:

-   -   determining if there is a side of the object in the view that is        non-flat, and if so, moving the dimensioning system or the        object so that the dimensioning system's field-of-view contains        a different portion of the object;    -   detecting if there is an obtuse angle that faces the point of        view, and if so, moving the dimensioning system or the object so        that the dimensioning system's field-of-view contains a        different portion of the object; and    -   detecting if there is another obtuse angle and/or a protrusion,        and if so, moving the dimensioning system or the object so that        the dimensioning system's field-of-view contains a different        portion of the object.

In another possible embodiment, the step of moving the dimensioningsystem or the object may include generating audio and/or visual messagesto guide a user to perform the movement. In select embodiments, theaudio and/or visual messages may include instructions for the user to(i) move the dimensioning system or the object in a particulardirection, (ii) move the dimensioning system or the object at aparticular speed, and/or (iii) cease moving the dimensioning system orthe object.

In another possible embodiment, the step of moving of the dimensioningsystem or the object may include an automatic movement of thedimensioning system or the object.

In another possible embodiment, the step of capturing, using thedimensioning system, a range image of the field-of-view may include:

-   -   projecting, using a pattern projector, a light pattern into the        field-of-view;    -   capturing, using a range camera, an image of the field-of-view,        the image comprising a reflected light-pattern; and    -   generating 3D data from the image of the reflected        light-pattern.

In another possible embodiment, the at least one range image maycomprise 3D data sufficient for dimensioning the object. In selectembodiments, the 3D data sufficient for dimensioning may include 3D datafrom all necessary views of the object to calculate the minimum boundingbox (MVBB). In other select embodiments, the 3D data may be from a viewof the object without any gaps in the reflected light-pattern.

In another possible embodiment, the dimensioning system may be handheld.For example, the dimensioning system may be incorporated into a handheldbarcode scanner.

In another aspect, the present invention embraces a dimensioning systemthat includes a dimensioning system with a single sensor. Thedimensioning system may generally include a pattern projector, a singlerange camera, and a processor. The pattern projector may be configuredto project a light pattern onto an object. The single range camera maybe configured to (i) capture an image of a reflected light-pattern inthe field-of-view, (ii) generate 3D data from the reflectedlight-pattern, and (iii) create a range image using the 3D data. Theprocessor may be communicatively coupled to the pattern projector andthe single range camera. The processor may be configured by software toautomatically determine the number of views captured of the object basedon one of three modes:

-   -   a first mode is automatically used if the object is a cuboid, or        has no protrusions and only one obtuse angle that does not face        the point of view, where the first mode captures a single view        of the object;    -   a second mode is automatically used if the object includes a        single obtuse angle that faces the point of view and no        protrusions, where the second mode captures two views of the        object; or    -   a third mode is automatically used if the object includes a        protrusion and/or more than one obtuse angle, overhang,        protrusion, or combinations thereof, where the third mode        captures more than two views of the object.

One feature of the dimensioning system may be that the processor isfurther configured to calculate dimensions of a minimum bounding boxfrom the range images from all of the automatically determined views.

In a possible embodiment, the dimensioning system may display and/ortransmit the dimensions of the minimum bounding box (MVBB) forcertification in commerce.

In another possible embodiment, the dimensioning system may be furtherconfigured to move the dimensioning system or the object so that thedimensioning system's field-of-view contains a different view of theobject after capturing one of the views until the determined number ofviews is captured. In select embodiments, the moving of the dimensioningsystem or the object is determined based on the processor beingconfigured for the following:

-   -   determining if there is a side of the object in the view that is        non-flat, and if so, moving the dimensioning system or the        object so that the dimensioning system's field-of-view contains        a different portion of the object;    -   detecting if there is an obtuse angle that faces the point of        view, and if so, moving the dimensioning system or the object so        that the dimensioning system's field-of-view contains a        different portion of the object; and    -   detecting if there is another obtuse angle and/or a protrusion,        and if so, moving the dimensioning system or the object so that        the dimensioning system's field-of-view contains a different        portion of the object.

In another possible embodiment, the moving of the dimensioning system orthe object may include generating audio and/or visual messages to guidea user to perform the movement. In select embodiments, the audio and/orvisual messages may include instructions for the user to (i) move thedimensioning system or the object in a particular direction, (ii) movethe dimensioning system or the object at a particular speed, and/or(iii) cease moving the dimensioning system or the object.

In select embodiments, the dimensioning system may be handheld. Forexample, the dimensioning system may be incorporated into a handheldbarcode scanner.

The foregoing illustrative summary, as well as other exemplaryobjectives and/or advantages of the invention, and the manner in whichthe same are accomplished, are further explained within the followingdetailed description and its accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 schematically depicts a block diagram of a dimensioning systemaccording to an embodiment of the present invention.

FIG. 2 graphically depicts the principle of sensing three dimensionsusing a spatially offset pattern projector and range camera according toan embodiment of the present invention.

FIG. 3 graphically depicts an implementation of a dimensioning system'spattern projector according to an embodiment of the present invention.

FIG. 4 graphically depicts the movement of the dimensioning systemand/or the object according to an embodiment of the present invention.

FIG. 5 graphically depicts a flow diagram illustrating a method fordimensioning an object according to an embodiment of the presentinvention.

FIG. 6 graphically depicts the two-dimensional view of an object thatcontains an obtuse angle according to an embodiment of the presentinvention.

FIG. 7 graphically depicts a flow chart representing how one (Mode 1),two (Mode 2), or three (Mode 3) views can be determined automaticallyaccording to an embodiment of the present invention so that the minimumbounding box may be provided for use in commerce.

DETAILED DESCRIPTION

The present invention embraces a method of dimensioning and adimensioning system with a single sensor (i.e. a single image sensor andcamera) that automatically switches modes for capturing the least amountof views for dimensioning various shaped objects. The method ofdimensioning and dimensioner of the instant disclosure is generallydesigned to automatically operate in and switch between one of threemodes:

-   -   a first mode is automatically used if the object is a cuboid, or        has no protrusions and only one obtuse angle that does not face        the point of view, where the first mode captures a single view        of the object;    -   a second mode is automatically used if the object includes a        single obtuse angle that faces the point of view and no        protrusions, where the second mode captures two views of the        object; or    -   a third mode is automatically used if the object includes a        protrusion and/or more than one obtuse angle, overhang,        protrusion, or combinations thereof, where the third mode        captures more than two views of the object.        Some advantages of using the disclosed method and system with        these three automatic modes may be to calculate a minimum        bounding box (MVBB) for use in commerce quickly, accurately and        with similar costs to a single mode dimensioning system. As        such, the present disclosure is designed to provide a        dimensioning method and system that will be marketable and        certifiable for use in commerce. The present disclosure improves        upon a device that is programmed to always make multiple        measurements in order to be certified for commerce to dimension        irregular objects. Thus, the instant disclosure may provide a        lower cost, yet inflexible approach that involves using a single        algorithm that requires the operator to make measurements from        different points of view (e.g. from the front and the side or        from one side and the other side, etc.). In addition, the        instant disclosure may describe an optimized and automated        approach in which information about the carton or object to be        dimensioned is used to determine how many views are required in        order to be certified for commerce. As such, a device        incorporating the methods and processes described herein may be        approximately the same cost as a standard device with a single        sensor but could provide unique certifiable in commerce features        in the optical dimensioning market.

An exemplary dimensioning system is shown in FIG. 1. The dimensioningsystem 10 includes a pattern projector 1 that is configured to project alight (e.g., infrared light) pattern into a field-of-view 2. The lightpattern typically comprises points of light arranged in a pattern (i.e.,point cloud). The points of light may be (i) sized identically ordifferently and (ii) may be arranged in some order or pseudo-randomly.The pattern projector may create the light pattern using a light source(e.g., laser, LED, etc.), a pattern creator (e.g., a mask, a diffractiveoptical element, etc.), and one or more lenses.

The dimensioning system 10 also includes a range camera 3 configured tocapture an image of the projected light pattern that is reflected fromthe range camera's field-of-view 4. The field-of-view of the rangecamera 4 and the field-of-view of the pattern projector 2 should overlapbut may not necessarily have identical shapes/sizes. The range camera 3may include one or more lenses to form a real image of the field-of-view4 onto an image sensor. Light filtering (e.g., infrared filter) may alsobe used to help detect the reflected pattern by removing stray lightand/or ambient light. An image sensor (e.g., CMOS sensor, CCD sensor,etc.) may be used to create a digital image of the light pattern. Therange camera may also include the necessary processing (e.g. DSP, FPGA,ASIC, etc.) to obtain 3D data from the light pattern image. As examples,and clearly not limited thereto, the range camera 3 may be based on oneor more of: structured light, stereo vision, time-of-flight, the like,and/or combinations thereof.

As shown in FIG. 2, the pattern projector 1 and the range camera 3 maybe spatially offset (e.g., stereoscopically arranged). The spatialoffset 8 allows for changes in the range 5 of an object 6 to be detectedas an image offset 7 on the range camera's image sensor. The spatialoffset 8 may be adjusted to change the image offset 7 to change theresolution at which range differences 5 may be detected. In this way,image offsets in the point-cloud pattern may be converted into 3D datafor objects within the dimensioning system's field-of-view.

The 3D data includes range values for each point of light in thepoint-cloud image. Further, range values between the points of light inthe point-cloud image may be interpolated to create what is known as arange image. A range image is a gray scale image in which each pixelvalue in the image corresponds to an estimated range between thedimensioning system and a point in the field-of-view. The range cameramay output 3D data in the form of point-cloud images or range images.

A range image may be analyzed using software algorithms running on thedimensioning system's processor 9 (see FIG. 1) to detect objects anddetermine the object's dimensions. In some cases these algorithms mayinclude steps to create a minimum bounding box (MVBB), which is acomputer model of a box that surrounds an object (e.g., an irregularlyshaped object) or a collection of objects (e.g., multiple boxes on apallet). In this case, the dimensioning system may return and evendisplay the dimensions of the MVBB.

Accurate dimensioning requires high-quality images of the reflectedpattern (e.g., point-cloud images). A high quality point-cloud image isone in which the points of light in the pattern are visible on aplurality of the object's surfaces. Low quality point-cloud images mayresult from a variety of circumstances. For example, the imaged patternmay not be visible one or more surfaces (e.g., surfaces that are blockedfrom the pattern projector) or fall outside the field-of-view of thepattern projector and/or the range camera. In another example, the lightpattern may be partially visible on a surface and/or lack sufficientpattern density (i.e., the number of visible points of light on thesurface). In yet another example, the lighting (e.g., glare, shadows) inthe object's environment and/or the object's reflectivity (e.g., darkobjects) may adversely affect the visibility of the light pattern.

FIG. 3 graphically depicts a dimensioning system 10 projecting a lightpattern 11 onto an object 6 in field-of-view 2. This depiction shows thedimensioning system 10 capturing a single view of object 6, as object 6is a cuboid (mode 1).

FIG. 4 illustrates how the movement 12 of the dimensioning system 10and/or movement 13 of the object 6 may help capture (i.e., sense,sample, etc.) 3D data. The movements 12 and/or 13 may allow for thecapture of 3D data from more portions or views of the object 6 thancould be obtained with a single view. Range images may be captured andthen combined to form a composite range-image. The composite range-imagehas 3D data from more points on the object. For example, all sides of anobject may be sampled during the moving process to obtain 3D data fromthe entire object. Further, gaps in the pattern (i.e., missing areas inthe pattern) may be filled in using this technique.

In one possible embodiment, the movement of the dimensioning systemand/or the object is automatic and does not require user participation.In this embodiment, the dimensioning system may be coupled to movementdevices (e.g., actuators, motors, etc.) that adjust the spatialrelationship between the dimensioning system and the object. In oneexample, the object 6 may be placed in a measurement area and thedimensioning system 10 may be moved around the object 12 to collectrange images from various perspectives or views as shown in FIG. 4. Inanother example, a fixed dimensioning system may collect range images asan object 6 is rotated (e.g., on a motorized turntable) 13 as shown inFIG. 4. In these cases, position information may be obtained from themovement device and used to help combine the range images to create the3D data.

In another possible embodiment, the movement of the dimensioning systemand/or the object is performed by a user. Here messages (e.g., audio,visual, etc.) may be generated by the dimensioning system's processorand conveyed to a user interface (e.g., screen, indicator lights,speaker, etc.). The user may follow the instructions provided by themessages to move the dimensioning-system/object. The instructions mayinclude messages to help a user know (i) how far to move thedimensioning-system/object, (ii) how fast to move thedimensioning-system/object, (iii) to move the dimensioning system/objectto a particular location, and (iv) how long to continue moving thedimensioning-system/object (e.g., when to stop moving). For example, thedimensioning system may be handheld and the user may move thedimensioning system to change perspective. In this case, thedimensioning system may be configured to gather tracking information(e.g., sense its position and orientation within the environment) tohelp combine the range images.

In general, the dimensioning system may be moved in a variety of ways asthe views and range images are captured. In some cases, however, thismovement may have certain requirements to facilitate combining. Forexample, movements may be limited to movements having a constant rangebetween the dimensioning system and the object, as changes in range canaffect the image size of the light-pattern/object. In another example,the movement may be limited to a certain path having a particularstarting point and ending point. This path may be determined using anexpected object size/shape.

The requirements for movement may be reduced through the use ofsimultaneous localization and mapping (SLAM). SLAM is a computeralgorithm that uses images (e.g., range images) of an environment toupdate the position of the imager (e.g., dimensioning system). Whenmoving a dimensioning-system, for example, SLAM algorithms may detectfeatures (i.e., landmarks) in a captured range image and then comparethese landmarks to landmarks found in previously captured range imagesin order to update the position of the dimensioning system. Thisposition information may be used to help combine the range images.

Combining range images may typically be achieved using image-stitching.Image-stitching refers to computer algorithms that transform, register,and blend a plurality of constituent images to form a single compositeimage. The image-stitching algorithms may first determine an appropriatemathematical model to relate the pixel coordinates for constituentimages to the pixel coordinates of a target composite-image surface(e.g., plane, cylinder, sphere, etc.). This involves transforming (e.g.,warping) the images to the target composite-image surface. Thetransformed images may then registered to one another (e.g., usingfeature detection and mapping) and merged (e.g., blended) to remove edgeeffects.

While range images have pixels to represent range instead of reflectedlight, they are like conventional digital images in most other regards.As such, the principles of image-stitching described thus far may beapplied equally to range images (or point-cloud images).

In one embodiment, the dimensioning system may be incorporated into ahandheld barcode scanner. Often parcels may have a bar code symbol foridentification of the individual item (serialized). As such, theincorporation of the instant dimensioning system into a barcode scannercould be a big speed advantage to look-up the bar code data on-line, orstored in a local database, to find out whether the dimensions havealready been determined at an earlier stage of the transport. A furtherenhancement would be for high-value items that are often counterfeited,to compare the stored dimensions to the measured dimensions and flag adiscrepancy.

FIG. 5 graphically depicts a flow diagram illustrating a method 100 fordimensioning an object. The method begins with positioning 20 adimensioning system and/or object so that at least a portion on anobject is contained within the dimensioning system's point-of-view. Themethod 100 then automatically determines 110 the number of viewsrequired to dimension the object. The number of views captured withrange images and dimensional data is automatically determined based onone of three modes: a first mode, a second mode, and a third mode basedon an algorithm. The first mode is automatically used if the object is acuboid, or has no protrusions and only one obtuse angle that does notface the point of view, where the first mode captures a single view ofthe object. The second mode is automatically used if the object includesa single obtuse angle that faces the point of view and no protrusions,where the second mode captures two views of the object. The third modeis automatically used if the object includes a protrusion and/or morethan one obtuse angle, overhang, protrusion, or combinations thereof,where the third mode captures more than two views of the object.

Once the number of required views is determined, the method firstcaptures 130 range images of an initial field-of-view. If the requirednumber of views is not captured, the dimensioning system and/or theobject is then moved 160 so that another portion of the object is withinthe field-of-view and another range image is captured 130. This processof moving and capturing is repeated until the required number of viewsand associated range images are captured 130.

Once the required number of views is captured, the plurality of rangeimages may then combined 170 to form a composite range-image, and thecomposite range-image may be used to dimension 190 the object.

In one exemplary embodiment, once the dimensioning 190 is complete, thedimensions of the minimum bounding box (MVBB) may be calculated 200. Inselect embodiments, these calculated dimensions of the MVBB may bedisplayed and/or transmitted 210.

In one exemplary embodiment, the dimensioning system may create messages150 to guide the movement of the dimensioning system and/or the objectas described previously. In select embodiments, this moving 150 of thedimensioning system or the object may be determined based on one or moreof the following:

-   -   determining if there is a side of the object in the view that is        non-flat, and if so, moving the dimensioning system or the        object so that the dimensioning system's field-of-view contains        a different portion of the object;    -   detecting if there is an obtuse angle that faces the point of        view, and if so, moving the dimensioning system or the object so        that the dimensioning system's field-of-view contains a        different portion of the object; and    -   detecting if there is another obtuse angle and/or a protrusion,        and if so, moving the dimensioning system or the object so that        the dimensioning system's field-of-view contains a different        portion of the object.

The present disclosure recognizes that particular features of an objectto be dimensioned (i.e. a carton or normal box) can be detected in thefirst view and, based on this analysis, change modes, then require twoor more points of view to be dimensioned. The present disclosure mayprovide a dimensioner that can be easily moved if handheld, oralternatively, a carton placed on a static dimensioner (e.g. auto cube)can be turned to a different orientation so that an automaticmode-switching device can be used to generate always the correctdimensions, particularly in countries with stringent requirements forcertification of dimensioning irregular objects.

Referring to Mode 1, if the carton is a cuboid or “normal” box, then nomatter from which point of view it is viewed, the same dimensionerresult will occur (within the measuring tolerance provided by thedevice, which may be called “d”). Consequently, a single image willproduce valid results for use in commerce.

Referring to Mode 2, if the object has an obtuse angle, then dependingon which view the dimensioning camera has, different sets of boundingbox dimensions result. If the obtuse angle is facing the camera, then a“shadow” or hidden area will result causing the dimensions of thebounding box to be larger than the minimum. The operator or system needsto be instructed to move the dimensioner or rearrange the object so thatanother view is obtained. As long as the other view does not have theobtuse angle facing the dimensioner, the result will be the smallestbounding box.

FIG. 6 graphically depicts the two-dimensional view of an object thatcontains an obtuse angle (angle F) according to an embodiment of thepresent invention. If the object is viewed from the right (side b) or ifthe object is flipped over and viewed with the obtuse angle facing away(side c down), then a smaller bounding box will result. It is thesmallest bounding box that is the one that must be reported for use incommerce. Assume for this discussion of FIG. 6, that the other end ofthe carton is identical and the remaining sides are flat andperpendicular to the ends. If the carton is viewed from above, asdepicted with the arrows (facing side c) then the dimensioner will notsee under the overhang and a “shadow” will be cast. This viewingscenario will produce a larger bounding box than if viewed from theright or if the carton is rearranged so that side “c” is down.

Referring to Mode 3, if the object has a side that is not flat, then itmay be overhanging another side and causing a hidden area. Consequently,another view would be required to see under the overhang. Similarly, ifthe object has a protrusion, then it may cause a shadow and potentially,a bounding box that is not the minimum. Again, another view would berequired to see under the protrusion. In some cases, especially if thereis more than one obtuse angle, overhang, or protrusion or if there is acombination, then the dimensioner must view the object from all threeorthogonal sides to be sure to capture the smallest bounding box.

In a handheld scenario, the operator may be instructed to move thedimensioner or rearrange the carton to obtain the second and/or thirdimages. In the case of a fixed dimensioner, the operator may beinstructed to rearrange the carton to obtain the second and/or thirdimage, or this movement may be automated.

Once the requisite number of views and images are collected, the devicemay simply compare the values and choose the set of dimensions thatproduce the smallest bounding box. If the operator does not collect therequisite images, then the device must not provide any dimensions (e.g.issue a static failure notice).

Referring now to FIG. 7, a summary of one embodiment of automatic modeswitching in a volume dimensioner is shown as a flowchart. The flowchartshows how on (Mode 1), two (Mode 2), or three (Mode 3) points of viewcan be determined automatically so that the dimensions of the MVBB canalways be provided. The overview of the disclosure is that thedimensioner automatically determines whether it has a safe view of theobject and can guarantee that the smallest bounding box is reported.Ultimately, it may be necessary to require three orthogonal views by theuser so that a customer will not be overcharged. Thus, the dimensionercould be certified for use in commerce

To supplement the present disclosure, this application incorporatesentirely by reference the following commonly assigned patents, patentapplication publications, and patent applications:

-   U.S. Pat. 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In the specification and/or figures, typical embodiments of theinvention have been disclosed. The present invention is not limited tosuch exemplary embodiments. The use of the term “and/or” includes anyand all combinations of one or more of the associated listed items. Thefigures are schematic representations and so are not necessarily drawnto scale. Unless otherwise noted, specific terms have been used in ageneric and descriptive sense and not for purposes of limitation.

The invention claimed is:
 1. A dimensioning system, comprising: a rangecamera configured to capture a first light pattern image projected ontoan object from a first view, in response to a determination that theobject has a flat side and an obtuse angle not facing a point of view ofthe dimensioning system and generate a first range image based on thefirst light pattern image; and a processor communicatively coupled tothe pattern projector and the range camera, wherein the processor isconfigured by software to: calculate a first set of dimensions of theobject based on the first range image; cause the range camera to capturea second light pattern image of the object from a second view, inresponse to a determination that the object has a non-flat side and anobtuse angle facing the point of view of the dimensioning system basedon the first set of dimensions and generate a second range image basedon the second light pattern image, wherein the second view is differentfrom the first view; calculate a second set of dimensions of the objectbased on the second range image; and determine a minimum bounding boxfor the object, defined by the projected light pattern onto the object,based at least on the first set of dimensions and the second set ofdimensions.
 2. The dimensioning system of claim 1, wherein in responseto determining the minimum bounding box for the object, the processor isconfigured by software to further: calculate a first bounding box forthe object based on the first set of dimensions; calculate a secondbounding box for the object based on the second set of dimensions;determine a smaller bounding box from the first bounding box and thesecond bounding box as the minimum bounding box.
 3. The dimensioningsystem of claim 1, wherein in response to determining the minimumbounding box for the object, the processor is configured by software tofurther: generate a composite image based on the first range image andthe second range image; and determine the minimum bounding box for theobject based on the composite image.
 4. The dimensioning system of claim1, wherein the processor is configured by software to: determine thatthe object comprises at least one of: (a) a protrusion, (b) the non-flatside, or (c) two or more obtuse angles based on the first range image;cause the range camera to capture a third light pattern image of theobject from a third view and generate a third range image based on thethird light pattern image, wherein the third view is different from thefirst view and the second view; and calculate a third set of dimensionsof the object based on the third range image; wherein determining theminimum bounding box for the object is based at least on the first setof dimensions, the second set of dimensions, and the third set ofdimensions.
 5. The dimensioning system of claim 4, wherein in responseto determining the minimum bounding box for the object, the processor isconfigured by software to further: calculate a first bounding box forthe object based on the first set of dimensions; calculate a secondbounding box for the object based on the second set of dimensions;calculate a third bounding box for the object based on the third set ofdimensions; and determine a smallest bounding box from the firstbounding box, the second bounding box, and the third bounding box as theminimum bounding box.
 6. The dimensioning system of claim 4, wherein inresponse to determining the minimum bounding box for the object, theprocessor is configured by software to further: generate a compositeimage based on the first range image, the second range image, and thethird range image; and determine the minimum bounding box for the objectbased on the composite image.
 7. The dimensioning system of claim 1,wherein the object comprises a bar code symbol, wherein the dimensioningsystem further comprises a bar code scanner, and wherein the processoris configured by software to further: cause the bar code scanner to scanthe bar code symbol; retrieve a set of historical dimensions of theobject from a database based on the bar code symbol; and compare theminimum bounding box with the set of historical dimensions of theobject.
 8. The dimensioning system of claim 7, wherein the processor isconfigured by software to further: determine that the minimum boundingbox is not consistent with the set of historical dimensions of theobject; and flag the object as counterfeit.
 9. The dimensioning systemof claim 1, wherein the range camera utilizes at least one of:structured light, stereo vision, or time-of-flight.
 10. The dimensioningsystem of claim 1, wherein the object is on a motorized turntable, andwherein in response to causing the range camera to capture the secondlight pattern image, the processor is configured by software to causethe motorized turntable to rotate.
 11. A method for dimensioning anobject using a dimensioning system, comprising: generating a first rangeimage of the object from a first view, in response to determining thatthe object has a flat side and an obtuse angle not facing a point ofview of the dimensioning system; calculating a first set of dimensionsof the object based on the first range image; generating a second rangeimage of the object from a second view, in response to determining thatthe object has a non-flat side and an obtuse angle facing the point ofview of the dimensioning system based on the first set of dimensions,wherein the second view is different from the first view; calculating asecond set of dimensions of the object based on the second range image;and determine a minimum bounding box for the object, defined by aprojected light pattern onto the object, based at least on the first setof dimensions and the second set of dimensions.
 12. The method of claim11, wherein determining the minimum bounding box for the object furthercomprises: calculating a first bounding box for the object based on thefirst set of dimensions; calculating a second bounding box for theobject based on the second set of dimensions; and determining a smallerbounding box from the first bounding box and the second bounding box asthe minimum bounding box.
 13. The method of claim 11, whereindetermining the minimum bounding box for the object further comprises:generating a composite image based on the first range image and thesecond range image; and determining the minimum bounding box for theobject based on the composite image.
 14. The method of claim 11, furthercomprises: determining that the object comprises at least one of: (a) aprotrusion, (b) the non-flat side, or (c) two or more obtuse anglesbased on the first range image; generating a third range image from athird view, wherein the third view is different from the first view andthe second view; and calculating a third set of dimensions of the objectbased on the third range image; wherein determining the minimum boundingbox for the object is based at least on the first set of dimensions, thesecond set of dimensions, and the third set of dimensions.
 15. Themethod of claim 14, wherein determining the minimum bounding box for theobject further comprises: calculating a first bounding box for theobject based on the first set of dimensions; calculating a secondbounding box for the object based on the second set of dimensions;calculating a third bounding box for the object based on the third setof dimensions; and determining a smallest bounding box from the firstbounding box, the second bounding box, and the third bounding box as theminimum bounding box.
 16. The method of claim 14, wherein determiningthe minimum bounding box for the object further comprises: generating acomposite image based on the first range image, the second range image,and the third range image; and determining the minimum bounding box forthe object based on the composite image.
 17. The method of claim 11,wherein the object comprises a bar code symbol, and wherein the methodfurther comprises: scanning the bar code symbol of the object;retrieving a set of historical dimensions of the object from a databasebased on the bar code symbol; and comparing the minimum bounding boxwith the set of historical dimensions of the object.
 18. The method ofclaim 17, further comprising: determining that the minimum bounding boxis not consistent with the set of historical dimensions of the object;and flagging the object as counterfeited.
 19. The method of claim 11,wherein generating the first range image is based on at least one of:structured light, stereo vision, or time-of-flight.
 20. The method ofclaim 11, wherein the object is on a motorized turntable, and whereingenerating the second range image of the object from the second viewfurther comprises rotating the motorized turntable.